Behaviour of biofuel addition on metallurgical properties of sinter

Blast furnace gas yield is essentially controlled by a gas-solid reaction phenomenon, which strongly influences hot metal manufacturing costs. As a result of rising prices for reducing agents on the international market, Companhia Siderurgica Nacional decided to inject natural gas into its blast furnaces. With more gas inside the furnace, the burden permeability became even more critical. To improve blast furnace gas yield, a new technological approach was adopted; raising the metallic burden reaction surface. To that end, a special sinter was developed with permeability being controlled by adding micropore nucleus forming agents, cellulignin coal, without, however, degrading its mechanical properties. This paper shows the main process parameters and the results from physicochemical characterisation of a sinter with controlled permeability, on a pilot scale, compared to those of conventional sinter. Gas flow laboratory simulations have conclusively corroborated the positive effects of micropore nucleus forming agents on enhancing sinter permeability.

Redução das emissões de gases efeito estufa no processo de fabricação do sinter

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Operational and environmental assessment on the use of charcoal in iron ore sinter production

A study was carried out into the use of charcoal as a supplementary fuel in the iron-ore sintering process. The primary fuel was coke breeze and anthracite with 0, 10, 25, 50 and 100% replacement of the energy input with charcoal to produce sinter. This was achieved by considering the carbon content of each fuel and its corresponding participation on fuel blending, in order to have the same carbon input in each test run. An extensive analysis of the environmental impact was carried out regarding the atmospheric pollutants characterization (dust, sulphur dioxide, nitrogen oxides, carbon monoxide, carbon dioxide, methane, total hydrocarbons, and dioxins and furans). Experimental results indicate that fuel blending where 50% of the heat input was provided by charcoal may be comparable with those using 100% coke, under normal sintering conditions, and may result in a 50% reduction on greenhouse gas emission. It was also observed that while dust, methane and hydrocarbons emissions increased, the total dioxins and furans, expressed as polychlorinated dibenzodioxins/furans, decreased approximately 50% when compared with operation with 100% coke.

Roman aqueducts and calcareous sinter deposits as a proxy for environmental changes

Die im Süden der Türkei gelegen, antiken Städte Aspendos und Patara, waren in der Römerzeit zwei bedeutende Handelszentren mit hoher Bevölkerungsdichte. Aquädukte versorgten beide Städte mit carbonathaltigem Wasser, wobei sich Kalksinter (Calciumcarbonat) in der Kanalrinne ablagerte. Dabei lagern sich im Wechsel eine hellere und dunklere Kalksinterlage ab, die als Sinterpaar bezeichnet wird. Um die Entstehung dieser Sinterpaare besser zu verstehen, und die beteiligten Prozesse mit saisonalen Veränderungen der Umwelt zu korrelieren, werden in der vorliegenden Arbeit laminierten Sinterablagerungen mit geochemischen und petrographischen Methoden untersucht.rnEntlang der Kanalrinne beider Aquädukte wurden an mehreren Stellen Proben entnommen. Es wurde untersucht in wieweit sich die Sinterstruktur aufgrund von Änderungen in der Neigung des Wasserkanals oder des Kanaltyps ändert. Um die Kristallform und die kristallografische Orientierung der Kristalle innerhalb der verschiedenen Sinterpaare zu untersuchen, wurden die entnommenen laminierten Kalksinterablagerungen mit Hilfe optischer Mikroskopie und EBSD (Electron Backscatter Diffraction) analysiert. Der Electron Probe Micro-Analyzer (EPMA) wurde verwendet, um saisonale Schwankungen der Hauptelementverteilung und den Anteil der stabilen Isotope im Wasser zu bestimmen. Die LA-ICP-MS (Laser Ablation-induktiv gekoppeltem Plasma-Massenspektrometrie) Spurenelementanalyse wurde durchgeführt, um kleinste Schwankungen der Spurenelemente zu finden. Basierend auf diesen Analysen wurde festgestellt, dass laminierten Kalksinterablagerungen laterale Änderungen in der Aquäduktstruktur und -neigung, jahreszeitliche Änderungen der Wasserchemie, der Temperatur sowie der Entgasungsrate während eines Jahres widerspiegeln. Die Kalksinterablagerungen zeigen eine deutliche Laminierung in Form von feinkörnig-porösen und grobkörnig-dichten Schichten, die trockene und nasse Jahreszeiten anzeigen. Feinkörnige Schichten zeigen eine hohe Epifluoreszenz aufgrund reichhaltiger organischer Inhalte, die vermutlich eine Folge der bakteriellen Aktivität während der warmen und trockenen Jahreszeit sind. Stabile Sauerstoff und Kohlenstoff-Isotop-Kurven entsprechen auch den jahreszeitlichen Schwankungen der verschiedenen Schichtenpaare. Vor allem δ 18O spiegelt jährliche Veränderungen in der Temperatur und jahreszeitliche Veränderungen des Abflusses wieder. Das wichtigste Ergebnis ist, dass die Periodizität von δ 18O durch Erwärmen des Wassers im Wasserkanal und nicht durch die Verdunstung oder der Brunnenwasser-Charakteristik verursacht wird. Die Periodizität von δ 13C ist komplexer Natur, vor allem zeigen δ 18O und δ 13C eine Antikorrelation entlang der Lamellenpaare. Dies wird wohl vor allem durch Entgasungsprozesse im Aquädukt verursacht. Die Ergebnisse der Spurenelemente sind meist inkonsistent und zeigen keine signifikanten Veränderungen in den verschiedenen Lamellenpaaren. Die Isotope Mg, Sr und Ba zeigen hingegen bei einigen Proben eine positive Korrelation und erreichen Höchstwerte innerhalb feinkörnig-poröser Schichten. Auch sind die Hauptelementwerte von Fe, K, Si und anderer detritischer Elemente innerhalb der feinkörnige-porösen Schichten maximal. Eine genaue Datierung der Kalksinterablagerungen ist wünschenswert, da der Zeitraum, in dem die Aquädukte aktiv waren, bereits archäologisch auf 200-300 Jahre festgelegt wurde. Paläomagnetische und 14C-Datierung geben keine brauchbare Ergebnisse. Die U/Th Isotopie wird durch eine hohe Anfangskonzentration von Th in den Proben behindert. Trotz dieser Schwierigkeiten war eine U/Th Datierung an einem Testbeispiel des Béziers Aquädukt erfolgreich. Mit Hilfe von analogen Untersuchungen an aktiven Wasserkanälen der heutigen Zeit, werden die Ablagerungsmechanismen und die geochemische Entwicklung der laminierten Sinterschichten besser verstanden. Ein weiteres laufendes Projekt dieser Doktorarbeit ist die Überwachung von Sinterabscheidungen und der saisonale Zusammensetzung des Wassers an einigen heute noch aktiven Aquädukten. Das Ziel ist die Untersuchung der jetzigen Calciumcarbonatabscheidungen in Aquäduktkanälen unter den heutigen Umgebungsbedingungen. Erste Ergebnisse zeigen, dass kleine regelmäßige jahreszeitliche Veränderungen in der Isotopenzusammensetzung des Wassers vorliegen, und dass die beobachtete Periodizität der stabilen Isotope aufgrund von Änderungen im eigentlichen Kanal entstanden ist. Die Untersuchung von Kalksinterablagerungen in römischen Aquädukten liefern vielversprechende Ergebnisse, für die Untersuchung des Paläöklimas, der Archaeoseismologie und anderer Umweltbedingungen in der Römerzeit. Diese Studie beschränkt sich auf zwei Aquädukte. Die Untersuchungen weiterer Aquädukte und einer Überwachung, der noch in Betrieb stehenden Aquädukte werden genauere Ergebnisse liefern.

High temperature deformation and densification in alumina-yttria composites

Pinning by second phase particles offers a potent means for limiting grain growth and enhancing superplasticity in alumina-based ceramics. In the present study, a colloidal technique was used to produce green bodies of alumina-yttria composites; at elevated temperatures, the yttria particles react with alumina to produce YAG particles. The densification and high temperature deformation characteristics of alumina-YAG composites were studied using conventional free sintering and sinter-forging, which involves the application of a compressive stress without any lateral constraints. It is shown that the YAG particles retard both densification and grain growth. The experiments indicate also that the presence of YAG particles does not significantly alter the stress exponent for creep deformation.

Low-voltage varistors from ZnO+CaMnO3 ceramics

: Varistors prepared from ZnO with CaMnO3 perovskite as the only forming additive, exhibit voltage-limiting current-voltage characteristics with nonlinearity coefficient alpha up to 380 at low voltages of 1.8-12 V/mm. High nonlinearity is observed only with a suitable combination of processing parameters. The most crucial of them are (i) initial formulation of ceramics and (ii) the sintering temperature and conditions of post-sinter annealing. An electrically active intergranular phase is formed between ZnO grains with the composition ranging from Ca4Mn6Zn4O17 to Ca4Mn8Zn3O19, which creates the n-p-n heterojunctions. The low-voltage nonlinearity originates as a result of higher concentration of Mn(III)/Mn(IV) present at the grain boundary layer regions, being charge compensated by zinc vacancies. Under the external electric field, the barrier height is lowered due to the uphill diffusion of holes mediated by the acceptor states. Above the turn-on voltages, the unhindered transport of charge carriers between grains generates high current density associated with large nonlinearity.

Influence of Bi 3+ ions in enhancing the magnitude of positive temperature coefficients of resistance in n-BaTiO3 ceramics

Bi3+ ions substituting at Ba-sites in a limited concentration range with another donor dopant occupying the Ti-sites in polycrystalline BaTiO3 enhanced the positive temperature coefficient of resistance (PTCR) by over seven orders of magnitude. These ceramics did not require normal post sinter annealing or a change to an oxygen atmosphere during annealing. These ceramics had low porosities coupled with better stabilities to large applied electric fields and chemically reducing atmospheres. Bi3+ ions limited the grain growth to less than 8 mum in size, they enhanced the concentration of acceptor-type trap centres at the grain-boundary-layer regions and maintained complete tetragonality at low grain sizes in BaTiO3 ceramics.

Combustion synthesis of yttria

Fine-particle, sinter-active yttria has been prepared by combustion of a redox compound, Y(N2H3COO)3·3H2O and mixtures of Y(N2H3COO)3·3H2O�NH4NO3 or NH4ClO4 as well as yttrium nitrate and hydrazine-based fuels. The fineparticle nature of the combustion-derived yttria has been investigated using powder density, particle size and BET surface area measurements. The uniaxially, cold-pressed fine-particle yttria when sintered at 1450�1500 °C achieved 98% theoretical density and showed a fine-grain (1�2 µm) microstructure.

Cytocompatibility property evaluation of gas pressure sintered SiAlON-SiC composites with L929 fibroblast cells and Saos-2 osteoblast-like cells

Although the oxide ceramics have widely been investigated for their biocompatibility, non-oxide ceramics, such as SiAlON and SiC are yet to be explored in detail. Lack of understanding of the biocompatibility restricts the use of these ceramics in clinical trials. It is hence, essential to carry out proper and thorough study to assess cell adhesion, cytocompatibility and cell viability on the non-oxide ceramics for the potential applications. In this perspective, the present research work reports the cytocompatibility of gas pressure sintered SiAlON monolith and SiAlON-SiC composites with varying amount of SIC, using connective tissue cells (L929) and bone cells (Saos-2). The quantification of cell viability using MTT assay reveals the non-cytotoxic response. The cell viability has been found to be cell type dependent. An attempt has been made to discuss the cytocompatibility of the developed composites in the light of SiC content and type of sinter additives. (C) 2011 Elsevier B.V. All rights reserved.

Densification kinetics, phase assemblage and hardness of spark plasma sintered Cu-10 wt% TiB2 and Cu-10 wt% TiB2-10 wt% Pb composites

The present work demonstrates the synthesis of Cu-10 wt% TiB2 composites with a theoretical density of more than 90% by tailoring the spark plasma sintering (SPS) conditions in the temperature range of 400-700 degrees C. Interestingly, 10 wt% Pb addition to Cu-10 wt% TiB2 lowers the sinter density and the difference in the densification behavior of the investigated compositions was discussed in reference to the current profile recorded during a SPS cycle. The sintering kinetics and phase assemblage were also discussed in reference to surface melting of the constituents prior to bulk melting temperature, temperature dependent wettability of Pb on Cu, diffusion kinetics of Cu as well as the formation of various oxides. An important result is that a high hardness of around 2 GPa and relative density close to 92% qtheoretical was achieved for the Cu-10 wt% TiB2-10 wt% Pb composite, and such a combination has never been achieved before using any conventional processing route.

Spark plasma sintering may lead to phase instability and inferior mechanical properties: A case study with TiB2

In contrast to the widely reported beneficial aspects of spark plasma sintering in developing materials with better properties, we report here two interesting aspects recorded with difficult-to-sinter titanium diboride: (a) in situ formation of second phase (TiB) and (b) inferior hardness (by similar to 30%) and elastic modulus (by similar to 20%) for spark plasma sintered TiB2, with respect to hot pressed TiB2. The formation of TiB is discussed with reference to the enhanced reaction kinetics in the presence of pulsed electric field. (C) 2013 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Microstructure Development, Nanomechanical, and Dynamic Compression Properties of Spark Plasma Sintered TiB2-Ti-Based Homogeneous and Bi-layered Composites

The growing threats due to increased use of small-caliber armor piercing projectiles demand the development of new light-weight body armor materials. In this context, TiB2 appears to be a promising ceramic material. However, poor sinterability and low fracture toughness remain two major issues for TiB2. In order to address these issues together, Ti as a sinter-aid is used to develop TiB2-(x wt pct Ti), (x = 10, 20) homogeneous composites and a bi-layered composite (BLC) with each layer having Ti content of 10 and 20 wt pct. The present study uniquely demonstrates the efficacy of two-stage spark plasma sintering route to develop dense TiB2-Ti composites with an excellent combination of nanoscale hardness (similar to 36 GPa) and indentation fracture toughness (similar to 12 MPa m(1/2)). In case of BLC, these properties are not compromised w.r.t. homogeneous composites, suggesting the retention of baseline material properties even in the bi-layer design due to optimal relief of residual stresses. The better indentation toughness of TiB2-(10 wt pct Ti) and TiB2-(20 wt pct Ti) composites can be attributed to the observed crack deflection/arrest, indicating better damage tolerance. Transmission electron microscope investigation reveals the presence of dense dislocation networks and deformation twins in alpha-Ti at the grain boundaries and triple pockets, surrounded by TiB2 grains. The dynamic strength of around 4 GPa has been measured using Split Hopkinson Pressure Bar tests in a reproducible manner at strain rates of the order of 600 s(-1). The damage progression under high strain rate has been investigated by acquiring real time images for the entire test duration using ultra-high speed imaging. An attempt has been made to establish microstructure-property correlation and a simple analysis based on Mohr-Coulomb theory is used to rationalize the measured strength properties.

纳米孔结构金属多孔材料研究进展

纳米孔结构金属多孔材料(以下简称金属纳米多孔材料)是近年来纳米技术及多孔材料科学领域引人注目的研究对象。本文综述了近年来金属纳米多孔材料的制备方法(粉末烧结法、脱合金法、胶晶模板法、斜入射沉积法等)、表征技术、应用现状以及最新的研究成果。指出了金属纳米多孔材料研究进程中存在的主要问题、发展前景及今后的研究方向。

Wear of hardfacing white cast irons by solid particle erosion

The response of three commercial weld-hardfacing alloys to erosive wear has been studied. These were high chromium white cast irons, deposited by an open-arc welding process, widely used in the mineral processing and steelmaking industries for wear protection. Erosion tests were carried out with quartz sand, silicon carbide grit and blast furnace sinter of two different sizes, at a velocity of 40 m s-1 and at impact angles in the range 20° to 90°. A monolithic white cast iron and mild steel were also tested for comparison. Little differences were found in the wear rates when silica sand or silicon carbide grit was used as the erodent. Significant differences were found, however, in the rankings of the materials. Susceptibility to fracture of the carbide particles in the white cast irons played an important role in the behaviour of the white cast irons. Sinter particles were unable to cause gross fracture of the carbides and so those materials with a high volume fraction of carbides showed the greatest resistance to erosive wear. Silica and silicon carbide were capable of causing fracture of the primary carbides. Concentration of plastic strain in the matrix then led to a high wear rate for the matrix. At normal impact with silica or silicon carbide erodents mild steel showed a greater resistance to erosive wear than these alloys. © 1995.